SIL & Partial Stroke Testing Solutions

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OSHA 29 CFR 1910.119 Process Safety Management (PSM) of Highly Hazardous Chemicals EPA 40 CFR 68 Chemical Accident Prevention Provisions

Hazards must be identified and appropriate measures taken to protect employees, the community and the environment. Compliance requires use of generally accepted good engineering practice.

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Safety valve as part of the Safety Instrumented System (SIS)

Safety System
Inputs
PT 1A PT 1B

Distributed Control System (DCS)

Inputs Outputs

Outputs

FT

Reactor

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Process Control System (BPCS) Controls the process Dynamic Failures revealed.

Safety Instrumented System (SIS) Reduces risk Passive Failures hidden To reduce risks associated with abnormal operation, availability must be high (probability of failure on demand, PFD, must be low) Availability confirmed by testing.

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Safety instrumented system (SIS) for process industries

SIS monitors the process and ensures safety by taking process to safe state when unconventional condition occur Safety engineers have been challenged to comply string safety requirements Intelligent ESD valve solutions help to reach the most demanding safety solution targets for final elements with minimum investment.

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Safety Standards To Comply With...

IEC 61508: Functional Safety of Electrical / Electronic / Programmable Electronic SafetyRelated Systems IEC 61511: Functional Safety Instrumented Systems for the Process Industry Sector

More redundant systems or more testing needed than before

Safety System

This leads to very high CAPEX (capital expense) and OPEX (operating expense) unless the latest technology is utilized

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UNCLASSIFIED

OREDA: Analysis of Safety Loop Failures

One study has shown that valves can represent as much as 50% of all SIS failures.
as much as

50% of all SIS failures

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P3
D1
0

P2
0 0 1 1 2 3 3 4

P1
0 0 0 1 1 2 3 3

D - Extent of Damage

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A1 E1 A2 D2 A1 E2 A2
3 2 1 1

D1: slight injury D2: severe injuries or one death D3: death of several persons D4: multiple deaths

E - Exposure Time
E1: seldom to relatively frequent E2: frequent to continuous

A - Hazard Avoidance
A1: possible under certain conditions A2: hardly possible

E1 D3 E2
4 3

P - Probability to occur
P1: very low P2: low P3: relatively high

D4
4 Consequence only method: D

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Risk matrix method: D + P

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Validation - PFD for Component

On-line diagnostics (= testing) Off-line diagnostics (= periodic maintenance)

Where:

d
MTBFd MTTR DC TIa TIm

= dangerous failure rate = 1/MTBFd = mean time between dangerous failures = mean time to repair = diagnostic coverage factor = test interval for automatic testing = test interval for manual testing (= maintenance period)

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Validation - The Safety Loop PFD

PFDSYS = PFDs + PFDL + PFDFE

Parameter 1 Sensors Parameter 2 Sensors Safety System

Parameter 1 Final Elements

Parameter 2 Final Elements

35%

15%

50%

(IEC 61508 target reliability guideline)

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UNCLASSIFIED

UNCLASSIFIED

SIL vs. Probability of Failure on Demand

Difference between SILs is an order of magnitude!
PFD = Probability to Fail on Demand What is the chance that the system fails

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Safety Integrity Level Probability of failure to perform its design (SIL) (How reliable the SIS needs to be to reduce function on demand a particular risk to an acceptable level)
4 3 2 1 (IEC /ISA) (IEC/ISA) (IEC/ISA) (IEC/ISA)

Safety Availability
(1-PFD) X 100%

I -5 to 10-4 10 10-4 to 10-3 10-3 to 10-2 10-2 to 10-1

99.99% to 99.999% 99.90% to 99.99% 99.00% to 99.90% 90.00% to 99.00%

Low demand Mode: Frequency of demand no greater than once per year and no greater than twice the proof check frequency

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Validation - Calculating PFD

Where,

d = dangerous failure rate

TI = testing interval (shutdown interval)

MTBFd = 50 years
SIL 1

SIL 2

SIL 3

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Validation - PFD with diagnostic coverage

MTBFd = 50 years, DCF = 75%

SIL 1

SIL 2

SIL 3

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Motivation to use partial valve stroke testing

Safety valve proof testing is mandatory activity in accordance of
IEC 61511 standard

Interval is defined according to the safety requirement of the plant BUT interval can be influenced with Product selection (hardware fault tolerance reduction) PST implementation (online testing of critical components)

Maximized production with PST

and at the same time safety is improved with intelligent PST valve sticking higher needed torque

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What is a safety valve?

ESD (emergency shut down)
valves or ESV (emergency venting) valves operating in demanding environment

Part of Safety Instrumented

System (SIS)

Defense against process

upsets

Operating only in trip situation

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Evolution of Safety Valve Testing

1.
Shutdown Testing

Interval may be too great Manual testing & documentation

2.

Bypass Testing

Safety function disabled during testing Manual testing & documentation Capital expense of additional valve & piping Possible Human error

3.

Partial Stroke Testing

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A solution to the dilemma: Run longer, test more often.

Bypass Shutdown Partial stroke

Demand for testing

Demand for Uptime

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Partial Stroke Testing Options

Mechanical Jammer Instrumentation Based Custom Panel Redundant Solenoids Digital Positioner + solenoid Control System Based Solution PST with an Intelligent Safety Valve Controller
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Partial Stroke Testing Options

Jammer Based Solution
Safety loop disabled during PST No real diagnostics information from the PST Testing requires manual work -> higher testing
costs

Human interaction always required for PST ->

safety risk

The safety solenoid is tested only during PST Full stroke test needs to be done manually

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Partial Stroke Testing Options

Instrumentation Based Solution
Complicated system with multiple potential failure
causes

Safety loop usually disabled during PST No real diagnostics information from the PST Testing requires manual work -> high testing costs Human interaction always required for PST ->
safety risk

In most cases the safety solenoid is not tested Full stroke test needs to be done manually

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Partial Stroke Testing Options

Redundant Solenoids
PST not available or it requires difficult, manual
configuration

No diagnostics The solenoids can not be tested automatically Full stroke test needs to be done manually

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Partial Stroke Testing Options

Positioner + Solenoid
Higher nuisance trip rate Solenoid can not be tested
automatically

Manual testing and interpretation of

test results

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Partial Stroke Testing Options

Control System Based Solution
Use DCS to initiate and Monitor PST Solenoid and Limit Switch configuration Diagnostics Limited to timing of PST Limited Safety Features

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Partial Stroke Testing Options

Intelligent PST Solution

Safety loop enabled during PST Diagnostics information from PST

Possibility to optimize ESD valve maintenance

Automated PST -> no testing costs Seamless Communication with DTM

or EDDL

HART Based

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Partial Stroke Testing Options

Intelligent PST Solution - continued

Human interaction not required for

PST more effective use of maintenance resources

Emergency trip captured Self documentation Improves safety while making life
easier with safety valves

3rd part certification (i.e. TV, Exida)

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Potential Issues with Conventional PST

Human interaction is typically
required

The safety system must be

disabled during testing

Testing creates high costs due to

human factors

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Potential Issues with Conventional PST

Testing intervals are long Little or no diagnostics
information is received when the tests are being performed

Safety solenoid valve might not

be tested at all

Complex instrumentation is often

required for conducting the tests

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Recent Improvements to intelligent PST

High Pneumatics Capacity
Improve SIL level by limiting need for pneumatic accessories with lower PFD values

Internal pneumatics test

Improve PFD of valve controller with internal testing that doesnt move the valve

PST stroke randomizer

Prevent buildup on the safety valve by randomizing the stroke size

Integrated Limit Switches Emergency trip test

Report safety test figures

Full interoperability with all major safety

systems and asset management systems

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Example of Diagnostics with Intelligent PST for predictive maintenance

Load factor and breakaway pressure
Trends collected from partial stroke tests Results shown test based not time based

Enables predictive maintenance

Potential valve failures can be detected in advance

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The valve is in original condition

TORQUE

Actuator output torque

Needed valve torque

0%

10 % 20 % 30 % 40 % 50 % 60 % 70 % 80 % 90 % 100 %

FULLY CLOSED

FULLY OPEN

Load factor trend for 10 latest PST's

100 % 90 % 80 % 70 % 60 % 50 % 40 % 30 % 20 % 10 % 0%

WARNING LIMIT

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When the needed valve torque exceeds the available actuator output torque, the valve is stuck
TORQUE
Actuator output torque

Needed valve torque

0%

10 % 20 % 30 % 40 % 50 % 60 % 70 % 80 % 90 % 100 %

FULLY CLOSED

FULLY OPEN

Load factor trend for 10 latest PST's

100 % 90 % 80 % 70 % 60 % 50 % 40 % 30 % 20 % 10 % 0%

WARNING LIMIT

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With less instrumentation, It can be easier, safer and more reliable

ESD ball valve with: PST Device Inductive proximity switches or position transmitter Filter regulator Volume booster ASCO solenoid valve Mounting panel Tandem mounting Tubing and fittings
Not needed Less tubing and fittings, since SOV and booster can be omitted
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Not Needed: Cv of SMART PST Device

Not needed, internal SOV

Not needed

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General Feature Summary of Intelligent PST

Pneumatic capacity [Cv] PST 100% Safety action test Pneumatics test Solenoid needed for trip Local user interface Single and double acting Energized to trip configuration Full diagnostics included Plug-in needed Diagnostics storage PST speed control Time stamping LCP Option Continuous Power Option Max 6.4 Cv Manual, auto & variable stroke Yes Yes No Yes Yes Yes, with SOV Yes No, DTM free of charge In the device Limiting execution time Based on AM system Yes Yes

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Seamless Integration into Control Systems

ABB 800xA

Emerson DELTA V/AMS Emerson 375 Field Communicator Foxboro IA Honeywell Experion

EDDL DD

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Rockwell

Yokogawa Centum/PRM

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Configuration and Testing Using Software Tools

Automated Intervals Pushbuttons DTM EDD

Emerson AMS

HART DD
375 HART handheld

3 7

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Future of Partial Stroke Testing

Fieldbus based PST

FOUNDATION for SIF (Safety Instrumented Functions) has just been

introduced to industry, only demo devices and systems exist

Current Configuration of some devices allows for ESD activity to

come from Current Safety Systems while communication is FF to DCS or Asset Management System

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TRAINING

24 VDC DO from Safety System

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mA

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RCI

mA

24 VDC

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Thank You

Questions????

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